Rainproof ventilated plastic sheet material for rainwear and method of making same

ABSTRACT

A RAINPROOF, VENTILATING MATERIAL IS PROVIDED UTILIZING TABS BENT AT THE LOCATION OF SLITS IN THE MATERIAL TO PROVIDE SHIELDED VENTILATION. THE MATERIAL ADJACENT EACH SLIT IS BENT TO FORM A PAIR OF FINGERNAIL-SHAPED TABS, THE DIRECTION OF THE PROJECTION OF ONE MEMBER OF THE PAIR FROM THE SURFACE OF THE MATERIAL BEING OPPOSITE THAT OF THE OTHER. THE PAIRS OF TABS ARE ALIGNED IN ONE DIRECTION, SO THAT THE TABS IN THAT ONE DIRECTION ALTERNATE IN THEIR DIRECTION OF PROJECTION, THUS, WHEN PROPERLY ORIENTED SHIELDING THE LOWER TABS BY THE UPPER TABS. THE MATERIAL IS FORMED FROM A SUBSTANCE WHICH MAY BE SUBJECTED TO MOLDING OR DEFORMING CONDITIONS, AND, WHICH, WHEN MOLDED TO THE DESIRED SHAPE MAY BE SUBJECTED TO SETTING CONDITIONS TO RETAIN THAT SHAPE PERMANENTLY. THE TABS ARE PERMANENTLY FORMED BY CUTTING THE SLITS AND BENDING THE TABS WHILE SUBJECTING THE MATERIAL TO MOLDING CONDITIONS, AS FOR EXAMPLE BY HEATING AND THE SETTING THE MATERIAL, AS FOR EXAMPLE BY COOLING.

Nov. 21, 1972 J. T. KOSKI 3,703,432

- RAINPRQOF VENTILATED PLAST SHEET MATERIAL FOR RAINWEAR AND M 0D INGSAME Fi Nov. 1970 INVENTOR JOHN T. KOSKI GE QCBZMt ATTO R N EY UnitedStates Patent m U.S. Cl. 161110 Claims ABSTRACT OF THE DISCLOSURE Arainproof, ventilating material is provided utilizing tabs bent at thelocation of slits in the material to provide shielded ventilation. Thematerial adjacent each slit is bent to form a pair of fingernail-shapedtabs, the direction of the projection of one member of the pair from thesurface of the material being opposite that of the other. The pairs oftabs are aligned in one direction, so that the tabs in that onedirection alternate in their direction of projection, thus, whenproperly oriented shielding the lower tabs by the upper tabs.

The material is formed from a substance which may be subjected tomolding or deforming conditions, and, which, when molded to the desiredshape may be subjected to setting conditions to retain that shapepermanently. The tabs are permanently formed by cutting the slits andbending the tabs while subjecting the material to molding conditions, asfor example by heating and then setting the material, as for example bycooling.

BACKGROUND OF THE INVENTION It is a well-known disadvantage of mostraincoats and rainwear on the market today that they are notselfventilating, but, when worn, retain evaporated perspiration and tendto make the wearer hot. The obvious reason for this is that to make asheet form material both ventilating and at the same time impervious torain is to make almost impossible conflicting demands of the material.Generally enhancing one of the two properties results in thedeterioration of the other. Previous efforts to provide a rainproofmaterial which was at the same time ventilating involve such complicatedstructure as to be prohibitive in cost. Even the more successful effortshave resulted only in a structure in which the ventilating propertieswere not permanent, but which properties deteriorated after a period oftime. An example of a complicated material is that disclosed in U.S.Pats. No. 2,697,832 and 3,228,821. An example of a prior art materialwhose rainproof properties were found to be nonpermanent is thatdisclosed in U.S. Pats. No. 315,806 and 3,296,626.

SUMMARY OF THE INVENTION The invention relates to rainproof, ventilatingmaterial which is greatly simplified in structure and which yetpositively provides ventilation for the wearer of the material and amethod for making the same. Specifically, the invention provides arainproof, ventilating material comprising a sheet having a plurality ofslits therethrough all oriented in the same direction, the portions ofthe sheet separated by each of the slits being deformed to provide apair of tabs for each slit, one of the tabs in each of the pairsprojecting outwardly from the surface of the sheet in a directionopposite to the projection of the other tab in the pair. This isaccomplished by cutting the slits while deforming the material on theopposite sides of the slit in opposite directions, all while thematerial is subjected to molding conditions, as for example by heating,the material preferably being the type which is molded into a givenshape by heating and subsequently by cooling.

Patented Nov. 21, 1972 Accordingly, it is an object of the invention toprovide a rainproof material having ventilating properties which may beretained during use over a long period of time.

It is a further object of this invention to provide rainproof materialof the above character which is greatly simplified in structure, therebyreducing the cost of manufacturing.

It is still another object of the invention to provide an inexpensivemethod for manufacturing the rainproof material of the above-describedcharacter.

It is still an additional object to provide an article of clothingprepared from the rainproof material of the invention.

Still further objects and advantages of the invention will appear as thedescription proceeds.

To the accomplishment of the foregoing and related ends, the invention,then, consists of the improved ventilating rainproof material andarticle of clothing hereinafter fully described and particularly pointedout in the claims, the annexed drawing and the following descriptionsetting forth in detail certain means for carrying out the invention,such disclosed means illustrating, however, but several of various waysin which the principles of the invention may be used.

BRIEF DESCRIPTION OF THE DRAWING In the annexed drawing:

FIG. 1 is a fragmentary plan view of a material fabricated in accordancewith the invention.

FIG. 2 is a fragmentary sectional view taken along the lines IIII ofFIG. 1, looking in the direction of the arrows.

FIG. 3 is a fragmentary, partially broken away, elevational view ofrollers utilized to perform the method of manufacturing of the materialof the invention; and

FIG. 4 is a fragmentary, partially broken away, sectional view takenalong the lines IV-IV of FIG. 3, looking in the direction of the arrows.

DESCRIPTION OF THE PREFERRED EMBODIMENT Material Referring to FIG. 1, inaccordance with the invention, the material comprises a flexiblewater-impervious sheet or film 10 having, using the terms for purposesof orientation, an outer surface 12 and an inner surface 14, the sheetbeing generally planar. The sheet is provided with a plurality of slits16 aligned in the same direction in rows with other slits, the slits ofone row preferably being parallel with the slits of another row. Theportions of the sheet 10 separated by a slit 16 are bent, molded, orotherwise deformed to produce fingernail-shaped tabs or louvers 18 and20. The term fingernail is intended to denote tabs which have thegeneral shape of a fingernail, the base of which forms the edge or lipof the slit 16, although the shape can in fact be hemispherical,semi-elliptical, or even triangular. In order to form a rainproof shieldor garment which still provides ventilating conditions, the tabs 18 allproject outwardly away from or convexly arcuate with respect to theouter surface, and are hinged at the top as seen in FIGS. 1 and 2. Thetabs 20 when oriented for wear project inwardly from surface 14 or areconcavely arcuate with respect thereto, and are hinged at the bottom, asseen in the drawings, FIGS. 1 and 2. Thus, considering the pairs of tabs18 and 20 provided by each slit 16, it will be apparent that, for thetabs aligned in any one column, such as column 22 (FIG. 1), the tabs 18and 20 alternate in the direction in which the project from the plane ofthe sheet.

The opening formed at each slit 16, as enlarged during molding of thetabs, permits ventilation to occur, the lower tabs 20 being shielded bythe convex upper tabs 18 from the rain when used in a rain shieldingitem. Obviously, the sheet is formed into a rainproof garment so thatthe tabs and slits are oriented as shown in FIG. 2, with the tabs 18being above the tabs 20.

Because of the nature of the material forming the sheet 10, which ishereinafter discussed, the tabs 18 and 20 are flexibly but permanentlybent away from the sheet so as to regain their original projectingpositions after being depressed under compressive loading. Thus,brushing the fabric against a surface will only temporarily tend toclose the tabs against the material so as to close off air accessthrough the slits.

METHOD OF MANUFACTURING Sheet 10 is a sheet form material havingmoldable properties, these properties permitting the tabs 18 and 20 tobe molded or deformed under molding conditions. Consequently, when themolded material is subsequently set by placing under the proper settingconditions, the tabs thus molded are permanently retained in form, evenwhen they are placed under slight compressive loading during normal use.Specifically, several ways may be used to form the tabs, dependent uponthe type of material used. Normally, the sheet 10 is a film of athermoplastic or heatsoftening material, or, alternatively, a clothfabric impregnated with a thermoplastic material. With such compositionsthe material is heated to moldable conditions, that is, to a temperatureabove the softening point. The material is then slit and molded ordeformed by suitable devices such as cooperating rollers. The materialis then cooled while deformed, and when it attains a temperature lowerthan the softening point, the molded form is permanently retained aslong as the softening point is not reached. Materials should preferablybe chosen having a softening point higher than the highest temperatureto which the article is to be subjected during use or storage.Alternatively, thermosetting or heat-settable materials may be used, forexample, vulcanizable rubber or a three-dimensional resin such as athermosetting polyester resin or a polyurethane resin may be used. Suchmaterials are set by continuing the application of heat even after thesoftened and molded form has been attained, the continued application ofheat causing the material to vulcanize or cross-link and to form apermanently infusible material. These materials have the advantage thatthe final product may be subjected to high temperatures without the lossof its shape. Some materials may be molded or embossed at roomtemperature, the pressure of the molding or embossing rolls beingsufficient to provide a molding action of the material, the shapereached being retained after the material leaves the rolls.

Among the materials which may be used in the present invention arerubber, synthetic rubber such as butadiene, acrylonitrile, neoprene,polysiloxane, polyurethane, or other synthetic materials such ascellophane, polyvinyl chloride, polyethylene, or polypropylene.

Specifically, in the case of a thermoplastic sheet, the rainproofventiliating material of the invention is formed by heating the sheet10, cutting a slit in the sheet for the location of each pair of tabs,bending the heated material on opposite sides of the slit in oppositedirections to form the pair of tabs, and allowing the bent material tocool while in the bent configuration. These steps are repeated so as toventilate the entire surface of the sheet with pairs of tabs, each ofwhich are aligned in the same direction.

These steps of manufacturing are preferably accomplished by progressingthrough the sheet in the direction of the alignment of the tabs so thatthe tabs are formed in columns, one row at a time. This lends itself tothe use of a pair of rollers to cut out the slits and to form the tabs,the rollers being shown in FIGS. 3 and 4. Specifically, a pair ofcounter-rotating rollers 40 and 42 are mounted on shafts 44 and 46,respectively. Each of the rollers is formed with alternating teeth 48and depressions 50, the rollers being geared and meshed together so thatwhere they come together, a tooth 48 from one roller engages and isdepressed into a groove or depression 50 of the other roller, while thegroove 50 of the one roller accommodates the tooth 48 of the otherroller. Preferably, the teeth 48 and the grooves 50 arefingernail-shaped to provide the corresponding shape to the tabs 18 and20. Thus, as a sheet S, FIG. 4, is fed between the nip of the rollers 40and 42, rows of tabs are formed, one row at a time, the bending of thematerial to form the tabs altermating in the direction in which thebending of the tab occurs from the plane of the sheet S. It will beapparent that by using the rollers 40 and 42, the cutting of the slitsand the bending of the tabs occur simultaneously.

To heat the rollers 40 and 42 to sufliciently high temperature to causethe sheet S to be molded in the cut and bent configuration, heatingducts 60 are provided in each of the rollers, the ducts carrying heatingelements or fluid sufficient to heat the material of the sheet S to atemperature moderately above the softening point.

Because of its very slightly thickness, the sheet S cools rapidly uponleaving the rollers, cooling below the softening point occurring withthe tabs still bent in their configuration as determined by the rollers40 and 42. Additionally, the material may be quickly cooled by directinga blast of cold air on the material as it leaves the hot forming rolls.

Other modes of applying the principle of my invention may be employedinstead of those explained, change being made as regards the means,methods and final products herein disclosed, provided those stated byany of the following claims or their equivalent be employed.

I therefore particularly point out and distinctly claim as my invention:

1. A flexible sheet form material selected from the group consisting ofthermoplastic resins, thermosetting resins, and rubbers, and suitablefor wearing apparel use having a rainproof ventilating louver assemblyprovided therein, said assembly comprising a slit having its lipsarcuately displaced in opposite directions to form a pair of tabs, theupper tab being arcuately convex and the lower tab arcuately concavewith respect to the surface which is to be subjected to rain.

2. A flexible sheet according to claim 1, wherein said tabs havefingernail shapes.

3. A flexible sheet according to claim 1, wherein said material iswater-impermeable.

4. A method for forming a rainproof ventilating louver assembly in aflexible sheet form material selected from the group consisting ofthermoplastic resins, thermosetting resins, and rubbers, which comprisesthe steps of:

(a) heating said material to a temperature at which it is moldable,

(1)) cutting a slit in said material and displacing the material onopposite sides of said slit in opposite directions to form a pair oftabs; and

(c) while said material is so arranged cooling said material to atemperature below that at which it is moldable, thereby enabling saidtabs to remain permanently formed in said material.

5. A flexible rainproof, ventilated material selected from the groupconsisting of thermoplastic resins, thermosetting resins, and rubbers,and suitable for Wearing apparel use comprising a sheet having aplurality of slits therethrough, the portions of said sheet separated byeach of said slits displaced to form a pair of tabs for each slit, oneof said tabs in each of said pair projecting outwardly from the surfaceof said sheet in a direction opposite to the projection of the other tabin said such pair.

6. The material as defined in claim 5, wherein said slits are paralleland said pairs are each aligned in the same direction.

7. The material as defined in claim 6, wherein each of said tabs alignedin said direction alternate in the direction 5 in which they projectfrom the surfaces of said sheet, said projecting direction beingmeasured from the plane of said sheet.

8. ,The material as defined in claim 5, wherein said slits are straightlines.

9. The material as defined in claim 5, wherein said tabs are flexiblybut permanently displaced from said sheet so as to regain their originalprojecting position after being depressed under compressive loading.

10. The material as defined in claim 5, wherein said tabs are fingernailshaped.

References Cited UNITED STATES PATENTS 6 Bailey 161111 Balfe 161-l11Lash et a1 287 X Hess 287 Stich 287 Ludwikowski 287 Ludwikowski 287Cowan 161-111 Chase 287 Chalon 161--110 PHILIP DIER, Primary ExaminerUS. Cl. X.R.

